Modular cargo container

ABSTRACT

A modular cargo container ( 100 ), which facilitates ease of assembly and disassembly and facile repair and replacement of damaged panels ( 3, 5 ). The container comprises a standard pallet ( 1 ) having a peripheral recess ( 25 ), and wall panels having a rock-in apparatus ( 31 ) for mating engagement into the pallet recess. A roof panel ( 11 ) secured to each of the wall panels ( 3, 5 ) serves to add structural stability to the container walls. In order to be better accommodated into an aircraft lower or middle deck hold, one or more wall panels ( 3, 5 ) arc suitably contoured.

FIELD OF THE INVENTION

The present invention relates to cargo containers.

BACKGROUND OF THE INVENTION

It is known in the art to provide storage for cargo to be transported in wide-bodied aircraft; among others also (a) specially contoured containers (is) are utilized as a part of the ULD (Unit Load Device) system utilized (at) for most wide-bodied aircraft's (airports). Prior art containers are generally constructed of lightweight materials, commonly aluminum. In addition, aircraft containers are of a lightweight construction to avoid adding unnecessarily to the aircraft load. There are a number of problems associated with the use of such containers, as set forth below.

Among these problems is that these containers, when empty, occupy substantial space at every airport. Furthermore, the presence of excess empty containers at some airports and the lack of sufficient containers at other airports represent a significant problem. This problem is currently solved by purchasing additional containers, transporting empty containers from one airport to another or by disassembling containers and transporting these piecemeal for re-assembly upon arrival. The prior art container structure is not specifically designed for ease of repeated disassembly and re-assembly and, consequently, some damage to various sections and parts inevitably results so as to render disassembly and re-assembly both costly and wasteful of materials, storage space and transport facilities.

As a consequence of the lightweight construction, and rough handling at the airport containers are subject to accidental damage. At virtually every airport there exist large numbers of costly spare and damaged containers awaiting transport to a repair facility. Transporting such large, empty containers is a costly and cumbersome problem. In addition, repair of the containers is costly and time consuming. In order to carry out a repair, the container must first be transported to a repair facility and there (disassembled) by removing a multitude of rivets, (and) nuts and bolts, a damaged panel or support member is repaired or replaced and the container is then returned (re-assembled. Returning the) empty (repaired container) to the airport (cargo area adds further to the cost).

There is, therefore, a lack in the art resulting from the high cost of transporting empty containers from airport to airport or to and from a repair facility. (In addition, the procedure of disassembling the container, necessary prior to effecting repairs, is both tedious and costly.)

DEFINITION

The term “rock-in” fastening apparatus or “rock-in” fastener is used to define a male fastening element arranged for mating engagement with a female fastening element, wherein a first portion of the male element is inserted into the female element, and “rocked” into position by partial rotation of the male element about the first portion, after which a second portion can be inserted thereinto, leading to a full locking engagement between the male and female elements; and whereby disengagement is obtained by a reversal of these steps.

SUMMARY OF THE INVENTION

The present invention seeks to provide a modular shipping container so as to solve many of the problems related to containers currently used (at) by most (airports) airlines.

A particular aim of the present invention is to provide a modular container, which facilitates relatively simple disassembly thereof, and transportation thereof and which, furthermore, simplifies the repair of damaged containers, the replacement of damaged components and the assembly of new containers due to the relatively easy transportation, disassembly and reassembly of the modular container and the easy storage of container components, instead of the backup of assembled containers. The present invention, moreover, enables the continued employment of the total or a part of the existing cargo pallet (base of containers) presently in use for cargo handling.

There is thus provided, in accordance with a preferred embodiment of the present invention, an improved cargo container, which includes:

-   -   a polygonal, rigid base member, configured so as to accommodate         rock-in type fastening apparatus along the periphery thereof;     -   a plurality of wall portions, (each) having rock-in fastening         apparatus formed along a predetermined edge portion thereof,         arranged for mating engagement with the base member so as to         become secured thereto, and further arranged to define a         container volume together with the base member; and     -   apparatus for fastening the plurality of wall portions to each         other.

According to a first embodiment of the present invention, the rock-in type fastening apparatus has a planar portion, fixably attached to the predetermined edge portion, and a toe-portion disposed perpendicularly to the planar portion and extending in operative orientation sideways in cross-section. The toe-portion is inserted with a rock-in motion of a wall portion into a peripheral seat track disposed in the topmost plane of the rigid base member. The peripheral seat track is defined in cross-section as a recess having a first edge member and a second edge member partially overlapping the recess. The toe-portion underlies and engages the first edge member to become secured thereto.

According to a variation of the first embodiment of the present invention, the rock-in type fastening apparatus is configured with a planar portion, a curved concave portion and a toe portion.

According to a second embodiment of the present invention, the apparatus for fastening the plurality of wall portions to each other includes a roof portion secured to each of the wall portions.

According to a third embodiment of the present invention, the wall portions are configured to provide an opening to enable loading of cargo into the container volume. According to a variation of the third embodiment of the present invention, the opening is closed with a flexible or a rigid covering fixably attached to a container portion.

According to a fourth embodiment of the present invention, the predetermined edge portion arranged for mating engagement with the base member, includes a sealing device located between the edge portion and the base member.

According to a fifth embodiment of the present invention, the wall portions include a covering member fixably attached to a frame member. According to a variation of the fifth embodiment of the present invention, the cargo container covering members and frame members are fabricated from a material selected from the list of aluminum, steel, a metal alloy, a plastic substance, reinforced plastic, wood, and laminated composites thereof.

According to a sixth embodiment of the present invention, the rigid, base member is a rectangular, rigid base member.

According to a seventh embodiment of the present invention, one or more of the wall portions maybe (is) configured with two or more planar surfaces to form a predetermined contoured shape. According to a variation of the seventh embodiment of the present invention the two or more planar surfaces (are) maybe fixably connected also by means of a hinge device to form a variable shape.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more fully understood and appreciated from the following detailed description, taken in conjunction with the drawings, in which:

FIG. 1 is an isometric view of a partially assembled modular container constructed in accordance with a preferred embodiment of the present invention;

FIG. 2 is a schematic plan view of a pallet forming the base of the container as depicted in FIG. 1;

FIG. 3 is a detailed view of portion “A” in FIG. 1, depicting a wall panel connected to an edge portion of the base of the container seen therein, by means of a rock-in fastener apparatus;

FIG. 4 is a schematic view of an aft panel of the container as depicted in FIG. 1;

FIG. 5 is a schematic view of an inboard panel of the container as depicted in FIG. 1;

FIG. 6 is a schematic view of a shear panel of the container as depicted in FIG. 1;

FIG. 7 is an isometric schematic view of an outboard panel of the container as depicted in FIG. 1;

FIG. 8 is a schematic view of a roof panel of the container as depicted in FIG. 1;

FIG. 9 is a profile view of a rock-in fastener constructed in accordance with an alternative embodiment of the invention; and

FIG. 10 is a three dimensional view of a modular container illustrating fastening of an inboard panel in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring now to FIG. 1, there is shown example of a three-dimensional view of a modular contoured container, referenced generally 100 which, in accordance with a preferred embodiment of the present invention, is a modular contoured aircraft cargo container. The construction is referred to as modular in so far as the various components are easily removed in the process of dismantling the container for (repair or) replacement of one or more damaged components or for transporting the dismantled container.

The modular container 100 includes a base 1, which, (preferably), is similar to an regular air cargo pallet (base) 1, an aft panel 3, an inboard panel 5, a shear panel 6, an outboard panel 70, and a roof panel 11. There is a roll-down flexible loading aperture covering 13 attached to the roof panel 11. An alternative to the flexible covering 13 is a rigid covering door panels (not shown) maybe fixably attached to (one or more of) the roof panel 11, the inboard panel 5 and the shear panel 6 by means of hinges, lockers etc.

Assembly of a modular container is commenced with the air cargo pallet base. Referring now to FIG. 2, there is shown a pallet base generally referenced 1, and a pallet edge 17 fixably attached to a pallet base plate 15 with rivets 19.

The pallet base edge provides a female fastening element, specifically a recess, into which a male element, specifically a rock-in fastener, is inserted and rocked into position. Referring now to FIG. 3, there is shown a cross-sectional view generally referenced 300 of portion “A” (FIG. 1) of pallet base edge 17 fixably attached with rivets (10) 19 to a pallet base 15 including a recess 25, a first edge member 27 and a second edge member 29 partially overlapping the recess. There is also shown a cross-sectional view depicting a rock-in apparatus 31 fixably attached with nuts and bolts 37 to a wall portion referenced 39. The rock-in apparatus 31 (includes a rock-in fastener 32 and an angle profile 35. The rock-in fastener 32) has a toe-portion 33 which engages the first edge member 27 of recess 25. In addition, a seal 20 is positioned between the angle profile 35 and the second edge member 29 of recess 25, to avoid the ingress of moisture.

In order to assemble the wall portion 39 on to the pallet base edge 17, the toe-portion 33 of the rock-in fastener (32) 31 is matingly engaged into the recess 25. Thereupon, the wall portion 39 is rocked or rotated into an upright position such that the toe-portion 33 engages the underside of the first edge member 27 and the underside of angle profile 35 engages seal 20 located on the upper surface of the pallet base edge 17.

Accordingly, the container generally referenced 100 (FIG. 1) includes wall portions, which are assembled on to the pallet base 1 in the above-mentioned manner and each wall portion is secured to adjacent wall portions with nuts and bolts. Thereafter, a roof portion 11 is secured with nuts and bolts to each of the wall portions thereby to provide additional structural stability to the container walls.

Should it become necessary to remove a particular wall portion, either to affect a repair to that wall portion or to disassemble the entire container, the relevant nuts and bolts, fastening the wall portion to the roof and to the adjacent wall portions, are removed. The wall portion is rocked outwards to disengage the rock-in fastener so that the wall portion can be removed from the container. Each of the wall portions are of a lightweight construction and fabricated from lightweight materials to provide a container, which is both rigid and able to carry a predetermined load, without needlessly adding weight to the container load. To achieve a lightweight construction, each of the wall portions is fabricated of an extruded profile frame, overlaid with a thin covering. Aluminum is the preferred material of construction for both the frame and the covering. Alternative materials are steel, plastic, plastic foam, reinforced plastic, wood and various laminates of these materials.

Referring now to FIG. 4, there is shown an aft panel 3, as depicted in FIG. 1, which is constructed of a frame 47 and reinforcing support members 49 and fixably attached thereto with rivets or screws 48 is a covering member 51. Furthermore, fixably attached to the aft panel 3 is a rock-in apparatus 31 for making a mating engagement with the recess 25 in the pallet base edge 17 as depicted in FIG. 3.

Referring now to FIG. 5, there is shown an inboard panel 5, as depicted in FIG. 1, which is constructed of a frame 53 and a reinforcing support member 55 and fixably attached thereto with rivets or screws 48 is a covering member 57. Furthermore, fixably attached to the inboard panel 5 is a rock-in apparatus 31 for making a mating engagement with the recess 25 in the pallet base edge 17 as depicted in FIG. 3.

Referring now to FIG. 6, there is shown a shear panel 6, as depicted in FIG. 1, which is constructed of a frame 59 and fixably attached thereto with rivets or screws 48 is a covering member 61. Furthermore, fixably attached to the (inboard) shear panel 6 is a rock-in apparatus 31 for making a mating engagement with the recess 25 in the pallet base edge 17 as depicted in FIG. 3.

Referring now to FIG. 7, an outboard panel, generally referenced 70, as depicted in FIG. 1, includes two panels, specifically a vertical panel 7 and a sloping panel 9 which maybe fixably attached one to the other with a hinge device 75. Additionally, there is shown a detailed view “B” of the rock-in apparatus 31 schematically showing the inclination of the rock-in apparatus 31 relative to the sloping panel 9. The hinge device 75 enables the outboard panel 70 to be folded over, with the vertical panel 7 lying flat over the sloping panel 9, or enables the outboard panel to lie flat for storage and transportation. The vertical panel 7 includes a frame member 65 and a reinforcing support member 69. A covering member 77 is fixably attached to the frame member 65 and to the support member 69 with rivets or screws (not shown). The lower sloping panel 9 includes a frame member 71 and a reinforcing support member 73. A covering member 79 is fixably attached to the frame member 71 and to the support member 73 with rivets (or screws) (not shown). Furthermore, fixably attached to the lower sloping panel 9 is a rock-in apparatus 31 for making a mating engagement with the recess 25 in the pallet base edge 17 as depicted in FIG. 3.

Each of the abovementioned panels is fixably secured to the adjacent panels by means of nuts and bolts.

Referring now to FIG. 8, there is illustrated a plan view of the roof panel generally referenced 11, as depicted in FIG. 1, which includes a frame 83 (not shown) to which an aluminum or other lightweight covering 81 is fixably attached with rivets 48.

Referring now to FIG. 9, there is shown a profile view of a rock-in fastener generally referenced 400, constructed in accordance with an alternative embodiment of the invention, which includes a vertical portion 41, a curved concave portion 43 and a toe portion 45.

Referring now to FIG. 10, to assemble a modular aircraft container, generally referenced 200, there is illustrated the aft panel 3, the shear panel 6, and the outboard panel 70, already engaged to the base pallet 1 with a rocking movement and thereafter secured to adjacent panels and to the roof panel 11 with nuts and bolts (not shown). The inboard panel 5 is shown as being rocked or rotated 8 into position after the rock-in fasteners 31 (32) (FIG. 3) are matingly engaged into the recess 25 of the pallet base edge 17. Thereafter, the inboard panel 5 is secured to the adjacent aft panel 3 and to roof panel 11 with nuts and bolts (not shown). Securing the roof panel 11 to each of the wall panels. (provides additional structural stability).

The container described hereinabove fulfills shortcomings of containers currently in use and generally known in the art. It will be appreciated by persons skilled in the art that the present invention facilitates transporting of disassembled containers especially as the disassembling and re-assembling process necessitates substantially fewer operations, is quicker and carries much less risk of damage to any of the components. During storage and transportation, disassembled modular containers will, moreover, occupy much less storage space than the presently utilized empty containers.

Furthermore, repair of damaged containers is more easily facilitated. Each damaged panel is readily removed from the modular container by detaching the damaged panel from the roof panel and the adjacent panels and by rocking the loosened panel outwards to detach the rock-in fastener from the pallet base recess. The roof panel holds the remaining wall panels in position while the damaged panel is being repaired or replaced. Container components, that is, panels and bases, can be stored at each airport repair facility without occupying excessive space and are constantly available for assembly as new containers or for replacement of damaged components. The present invention represents, therefore, a substantial reduction in provision of additional containers, handling, transportation, repair, and replacement costs and a decrease in the need for storage space.

It will be appreciated by persons skilled in the art that the present invention is not limited by the drawings and description hereinabove presented. Rather, the invention is defined solely by the claims that follow. 

1. A cargo container which includes: a polygonal, rigid base member, configured so as to accommodate rock-in type fastening apparatus along the periphery thereof; a plurality of wall portions, each having rock-in fastening apparatus formed along a predetermined edge portion thereof, arranged for mating engagement with said base member so as to become secured thereto, and further arranged to define a container volume together with said base member; and apparatus for fastening said plurality of wall portions to each other.
 2. A cargo container according to claim 1, wherein said rock-in type fastening apparatus has a planar portion, fixably attached to said predetermined edge portion, and a toe-portion disposed perpendicularly to said planar portion and extending in operative orientation sideways in cross-section, and wherein said toe-portion is inserted with a rock-in motion of said wall portion into a peripheral seat track disposed in the topmost plane of said rigid base member, said peripheral seat track being defined in cross-section as a recess having a first edge member and a second edge member partially overlapping said recess, and wherein said toe-portion underlies and engages said first edge member to become secured thereto.
 3. A cargo container according to claim 2, wherein said rock-in type fastening apparatus is configured with a planar portion, a curved concave portion and a toe portion.
 4. A cargo container according to claim 1, wherein said apparatus for fastening said plurality of wall portions to each other includes a roof portion which is secured to said wall portions, thereby to provide additional structural stability thereto.
 5. A cargo container according to claim 1, wherein said wall portions are arranged to provide an opening to enable loading of cargo into said container volume.
 6. A cargo container according to claim 5, wherein said opening is closed with a covering fixably attached to a container portion, said covering selected from the list of a flexible covering and a rigid covering.
 7. A cargo container according to claim 1, wherein said predetermined edge portion arranged for mating engagement with said base member, includes a sealing device located between said edge portion and said base member.
 8. A cargo container according to claim 1, wherein each of said wall portions includes a covering member fixably attached to a frame member.
 9. A cargo container according to claim 8, wherein said covering member and said frame member are fabricated from a material selected from the list of aluminum, steel, a metal alloy, a plastic substance, foam plastic, reinforced plastic, wood, and laminated composites thereof.
 10. A cargo container according to claim 1 wherein said polygonal, rigid base member is a rectangular, rigid base member.
 11. A cargo container according to claim 1, wherein wall portions may fit all types and sizes of contourar, rectangular, igloo shaped & other containers. (at least one of said wall portions is configured with at least two planar surfaces to form a predetermined contoured shape.)
 12. (A cargo container according to claim 11, wherein said at least two planar surfaces are fixably connected by means of a hinge device to form a variable shape). 